Cushioning conversion machine and method

ABSTRACT

A cushioning conversion machine ( 20 ) including a conversion assembly ( 30 ) which converts a continuous sheet of multi-ply stock material ( 22 ) into a three dimensional cushioning product ( 32 ) and a stock supply assembly ( 550 ) which supplies the multi-ply stock material ( 22 ) to the conversion assembly ( 30 ). The conversion assembly ( 30 ) includes a forming assembly ( 52 ) which inwardly turns lateral portions of the stock material ( 22 ) as the stock material ( 22 ) travels therethrough in a downstream direction. The stock supply assembly ( 550 ) includes a separating device ( 574 ) and/or constant-entry device ( 580 ) designed to minimize tearing due to excessive tension in the lateral regions of the stock material ( 22 ). Additionally or alternatively, the forming assembly ( 52 ) includes a shaping member ( 590 ) having protrusions in its turning perimeter and/or holding surface to modify the shape of the cushioning product. Another embodiment of stock supply assembly ( 350 ) includes a stock-dispensing device ( 370 ) which dispenses the multi-ply stock material ( 22 ) from a continuous sheet thereof and a transversely extending member which is positioned to engage at least one of the plies of the dispensed multi-ply stock material ( 22 ). The transversely extending member has end portions which are inwardly tapered relative to the central portions of the member and towards the adjacent ends of the member. The inwardly tapered lateral end portions being positioned to engage the ends of the lateral portions of the at least one ply of the stock material ( 22 ).

RELATED APPLICATION DATA

[0001] This application is a continuation of patent application Ser. No.09/702,981, filed Oct. 31, 2000, which is hereby incorporated herein byreference in its entirety, and which is a continuation of patentapplication Ser. No. 09/229,459 filed Jan. 12, 1999, which claims thebenefit of Provisional Application No. 60/085,721 filed May 15, 1998,and Provisional Application No. 60/071,212 filed Jan. 12, 1998.

FIELD OF THE INVENTION

[0002] The present invention relates generally as indicated to acushioning conversion machine and method. More particularly, the presentinvention relates to a separator device, a constant-entry device, and/ora shaping member for use in a cushioning conversion machine or method.

BACKGROUND OF INVENTION

[0003] In the process of shipping an item from one location to another,a protective packaging material is typically placed in the shippingcase, or box, to fill any voids and/or to cushion the item during theshipping process. Some conventional commonly used protective packagingmaterials are plastic foam peanuts and plastic bubble pack. While theseconventional plastic materials seem to adequately perform as cushioningproducts, they are not without disadvantages. Perhaps the most seriousdrawback of plastic bubble wrap and/or plastic foam peanuts is theireffect on our environment. Quite simply, these plastic packagingmaterials are not biodegradable and thus they cannot avoid furthermultiplying our planet's already critical waste disposal problems. Thenon-biodegradability of these packaging materials has becomeincreasingly important in light of many industries adopting moreprogressive policies in terms of environmental responsibility.

[0004] These and other disadvantages of conventional plastic packagingmaterials has made paper protective packaging material a very popularalternative. Paper is biodegradable, recyclable and renewable; making itan environmentally responsible choice for conscientious industries.While paper in sheet form could possibly be used as a protectivepackaging material, it is usually preferable to convert the sheets ofpaper into a relatively low density pad-like cushioning dunnage product.This conversion may be accomplished by a cushioning conversion machine,such as that disclosed in U.S. Pat. No. 5,322,477. This patent isassigned to the assignee of the present application and its entiredisclosure is hereby incorporated herein by reference.

[0005] The cushioning conversion machine disclosed in U.S. Pat. No.5,322,477 comprises a conversion assembly which converts multi-ply stockmaterial into a three-dimensional cushioning product and a stock supplyassembly which supplies the multi-ply stock material to the conversionassembly. The conversion assembly includes the forming assembly whichinwardly turns the lateral regions of the stock material as it travelsdownstream therethrough. This inward turning results the lateral regionsof the stock experiencing edge tension which sometimes results inripping or tearing of the stock material.

[0006] A need remains for further improvements to prevent excessive edgetension and/or the tearing associated therewith. This need is especiallycritical for the conversion of lesser quality and/or short fiber paper.Additionally or alternatively, a need remains for other improvements tothe cushioning conversion machine to work in conjunction withtension-distributing devices or otherwise improve or enhance theconversion process.

SUMMARY OF THE INVENTION

[0007] The present invention provides a stock supply arrangement whichprevents the stock material from abruptly experiencing inward turningjust downstream of the stock supply assembly, or more particularly theseparating device. The stock supply arrangement of the present inventionallows a more gradual transition between the supply of the stockmaterial to the conversion assembly and the inward turning of lateralregions of the stock material by the conversion assembly. Such a gradualtransition is believed to reduce edge-tension in the stock materialand/or otherwise enhance the conversion process.

[0008] More particularly, the present invention provides a cushioningconversion machine comprising a conversion assembly which converts amulti-ply stock material into a three dimensional cushioning product anda stock supply assembly which supplies the multi-ply stock material tothe conversion assembly. The conversion assembly includes a formingassembly which inwardly turns lateral regions of the stock material asthe stock material travels therethrough in a downstream direction.Preferably, the forming assembly comprises a chute and a shaping memberpositioned at least partially within the chute with the stock materialpassing through the chute and around the shaping member as it travelsthrough the forming assembly.

[0009] According to one aspect of the invention, the stock supplyassembly includes a stock-dispensing device which dispenses themulti-ply stock material from a continuous sheet or roll thereof and aseparating device which separates the plies of the dispensed stockmaterial upstream of the forming assembly. The separating deviceincludes a plurality of transversely extending separating members whichare positioned to engage respective plies of the multi-ply stockmaterial. At least some of the separating members (and preferably all)are shaped to permit an initial inward turning of the lateral regions ofthe stock material in the same direction as the forming assembly. Inthis manner, there is a more gradual transition between the supply ofthe stock material to the machine's conversion assembly and the inwardturning of lateral regions by the conversion assembly.

[0010] The preferred separating members are shaped such that tension issubstantially evenly distributed throughout the full width of the stockmaterial. At least some (and preferably all) of the separating membershave a bowed or curved configuration and thus do not follow a transverselinear path perpendicular to the upstream-downstream direction. Thedirection of concavity of the bowed separating members corresponds tothe direction which the lateral regions of the stock material areinwardly turned. The magnitude of concavity of the bowed separatingmembers is such that there will be a gradual transition between thecurvature of the stock material from the separating device to theforming assembly.

[0011] In the preferred cushioning conversion machine, the stock supplyassembly is adapted to supply stock material which is between 25 to 35inches wide and more preferably between 27 and 30 inches wide. Theconversion assembly converts this stock material into a cushioningproduct which is approximately 8 to 9 inches wide. With such acushioning conversion machine, the radii of curvature of the bowedseparating members is preferably between 26 and 34 inches, morepreferably between 27 and 33 inches, and even more preferably between 28and 32 inches. The radii of curvature preferably varies between thebowed separating members, and preferably increases from the separatingmember which engages the ply of stock material which forms the inner plyin the cushioning product to the separating member which engages the plyof stock material which forms the outer ply in the cushioning product.Additionally, the radii of curvature of the separating members arepreferably concentric to create a “bull's eye” arrangement.

[0012] According to another aspect of the invention, the stock supplyassembly includes a constant-entry device which also functionstemporarily as a force dampening device during a high tension situation,such as during a start-up situation when it is necessary to overcome thestarting momentum of the stock roll. The constant-entry deviceautomatically returns to its normal operating position once thehigh-tension situation is relieved. When the stock material passing overthe constant entry device is subjected to high tension, a guide rollerof the constant entry device moves against a biasing force to limit thetension on the paper. During such yielding movement of the guide roller,the entry point is shifted in a range that is great enough to providesufficient tension relief while at the same time being limited enough toinsure adequate conversion of the stock material. Preferably the rangeof permitted movement is between 2½ inches and 4½ inches and isaccomplished by the spring-loading of the guide roller which engages thestock material.

[0013] According to another aspect of the invention, the shaping memberof the forming assembly has portions which define a turning perimeteraround which the lateral regions of the sheet-like stock material areinwardly turned and portions which define a holding surface that holdsthe central regions of the stock material as its lateral regions areinwardly turned. The turning perimeter includes co-planar portions andat least one protrusion which projects beyond these co-planar portions.The protrusion is preferably positioned adjacent the downstream end ofthe shaping member and within the chute. Additionally or alternatively,the holding surface includes at least one protrusion which projectsbeyond a plane extending from the downstream edge of the holding surfaceto the upstream edge of the holding surface.

[0014] According to a further aspect of the invention, a separatingdevice includes a plurality of transversely extending separating memberswhich are positioned to engage respective plies of the mutli-ply stockmaterial, at least one of which has end portions and a central portiontherebetween. The end portions are inwardly tapered relative to thecentral portion towards the respective ends of the member and arepositioned to engage the ends of the lateral portions of at least one ofthe plies of stock material. Preferably, at least two the transverselyextending members of the separating device have inwardly tapered lateralend portions. More preferably an outer transversely extending member(positioned to engage an outer ply of the multi-ply stock material) andan inner transversely extending member (positioned to engage an innerply of the multi-ply stock material) both have inwardly tapered lateralend portions. Also preferably, an intermediate transversely extendingmember (positioned to engage an intermediate ply of the multi-ply stockmaterial) does not include inwardly tapered lateral end portions.

[0015] The separating members including the inwardly tapered lateral endportions preferably comprise a non-rotatable rod and a sleeve. Thesleeve is rotatably mounted around the rod and defines at least thecentral portion of the separating member. In one embodiment of theinvention, the sleeve defines only the central portion and theseparating member includes end caps which define the inwardly taperingend portions. In another embodiment of the invention, the sleeve definesboth the central portion and the inwardly tapering end portions of theseparating member.

[0016] In the preferred embodiment, the transversely extending memberhaving the inwardly tapered end portions is incorporated into themachine's separating device. However, the incorporation of such a memberinto a cushioning conversion machine which does not include a separatingdevice is possible with, and contemplated by, the present invention. Thestock supply assembly of such a machine would include a stock-dispensingdevice which dispenses the multi-ply stock material from a continuoussheet thereof and the transversely extending member would be positionedto engage at least one of the plies of the dispensed mutli-ply stockmaterial.

[0017] The present invention also provides a cushioning conversionmethod comprising the steps of supplying a multi-ply stock material andconverting the stock material into a three dimensional cushioningproduct. The converting step includes inwardly turning lateral portionsof the stock material as the stock material travels in a downstreamdirection. The supplying step includes dispensing the stock materialfrom a continuous sheet of multi-ply stock material and engaging atleast one ply of the dispensed stock material with a transverselyextending member which allows inward urging of the lateral end portionsof the at least one ply in the same direction as the inwardly turningstep of the converting step. Preferably, the supplying step alsoincludes the step of separating the plies of stock material and theengaging step is performed at the same time as said separating step.

[0018] The foregoing and other features of the invention are hereinafterfully described and particularly pointed out in the claims. Thefollowing description and annexed drawings setting forth in detail acertain illustrative embodiment of the invention, this being indicative,however, of but a few of the various ways in which the principles of theinvention may be employed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 is a side view of the cushioning conversion machinedisclosed in U.S. Pat. No. 5,322,477, the machine being shown positionedin a horizontal manner, loaded with stock material, and with an outerhousing side wall removed for clarity of illustration.

[0020]FIG. 2 is an opposite side view of the cushioning conversionmachine shown in FIG. 1.

[0021]FIG. 3 is a top plan view of the cushioning conversion machine ofFIG. 1, without stock material being loaded and as seen along line 3-3in FIG. 1.

[0022]FIGS. 4, 5, and 6 are top, upstream end, and side views,respectively, of a shaping member used in the cushioning conversionmachine shown in FIG. 1.

[0023]FIG. 7 is a side schematic view of a stock supply assemblyaccording to the present invention, the stock supply assembly includinga separating device with an inner separating member, an outer separatingmember, and an intermediate separating member.

[0024]FIG. 8 is a top view of the outer or inner separating member.

[0025]FIG. 9 is a top view of end cap of the outer separating member.

[0026]FIG. 10 is a top view of another outer or inner separating memberwhich may be used in a stock supply assembly according to the presentinvention.

[0027]FIG. 11 is a side view of another embodiment of stock supplyassembly according to the present invention.

[0028]FIG. 12 is a downstream end view of a separating device of thestock supply assembly according to the present invention.

[0029]FIG. 13 is a top view of the separating device shown in FIG. 12.

[0030]FIG. 14 is a side view of a component of a constant entry deviceof the stock supply assembly according to the present invention.

[0031]FIGS. 15, 16 and 17 are top, upstream end, and side views,respectively of a shaping member according to the present invention.

DETAILED DESCRIPTION

[0032] The cushioning conversion machine disclosed in U.S. Pat. No.5,322,477 is shown in FIGS. 1-3 and is indicated generally at 20. InFIGS. 1 and 2, the machine 20 is shown positioned in a horizontal mannerand loaded with a roll 21 of sheet-like stock material 22. The stockmaterial 22 may consist of three superimposed webs or layers 24, 26, and28 of biodegradable, recyclable and reusable thirty-pound Kraft paperrolled onto a hollow cylindrical tube 29. A thirty-inch roll of thispaper, which is approximately 450 feet long, will weigh about 35 poundsand will provide cushioning equal to approximately four 15 ft³ bags ofplastic foam peanuts while at the same time requiring less thanone-thirtieth the storage space.

[0033] As is explained in more detail below, the machine 20 includesconversion assemblies (hereinafter collectively referred to as theconversion assembly 30) which convert the stock material 22 into acontinuous unconnected strip having lateral pillow-like portionsseparated by a thin central band. This strip is connected along thecentral band to form a connected strip which is cut into sections 32 ofa desired length. The cut sections 32 each include lateral pillow-likeportions 33 separated by a thin central band and provide an excellentrelatively low density pad-like product which may be used instead ofconventional plastic protective packaging material.

[0034] The machine 20 includes a housing, indicated generally at 36,having an upstream or “feed” end 38 and a downstream or “discharge” end40. The terms “upstream” and “downstream” in this context arecharacteristic of the direction of flow of the stock material 22 throughthe machine 20. The housing 36 is positioned in a substantiallyhorizontal manner whereby an imaginary longitudinal line or axis 42 fromthe upstream end 38 to the downstream end 40 would be substantiallyhorizontal.

[0035] The housing 36 includes side walls 37, a top or cover wall 39, abase plate or wall 43 and two end walls 44 and 46. The frame base wall43 is generally rectangular and extends from the upstream end 38 to thedownstream end 40 of the housing 36 in a generally horizontal plane.Although not perfectly apparent from the illustrations, the first orupstream wall 44 may be more specifically described as a thinrectangular wall having a rectangular stock inlet opening 47 passingtherethrough. Alternatively, instead of the end wall 44, the side andbase walls 37 and 43 may have upstream inwardly turned end sections thatform a rectangular border around the stock inlet opening 47. The secondor downstream end wall 46 is generally rectangular and planar andincludes a relatively small rectangular outlet opening.

[0036] The first frame end wall 44 extends generally perpendicular inone direction from the upstream end of the frame base wall 43. In theillustrated embodiment of FIGS. 1 and 2, this direction is upward. Thesecond end wall 46 is preferably aluminum and extends in generally thesame perpendicular direction from the downstream end of the frame basewall 43. In this manner, the housing 36 is basically “C” shape and oneside of the frame base wall 43, which in this embodiment is the lowerside, is a flat uninterrupted surface. The housing 36 also includes abox-like extension 49 removably attached to a downstream portion of thebase wall 43. Although not shown in all of the drawings, the frame maybe enclosed by a sheet metal housing, including side walls 37 and a topwall or cover 39.

[0037] The machine 20 further includes a stock supply assembly 50, aforming assembly 52, a feed assembly 54 powered by a feed motor 55, acutting assembly 56 powered by a cutter motor 57, and a post cuttingassembly 58. In operation of the machine 20, the stock supply assembly50 supplies the stock material 22 to the forming assembly 52. Theforming assembly 52 causes inward rolling of lateral regions of thesheet-like stock material 22 to form the lateral pillow-like portions 33of the continuous strip. The feed assembly 54 pulls the stock material22 from the stock roll 21, through the stock supply assembly 50, andthrough the forming assembly 52 and also connects or stitches thecentral band of the strip to form the connected strip. As the connectedstrip travels downstream from the feed assembly 54, the cutting assembly56 cuts the strip into sections 32 of a desired length. These cutsections 32 then travel through the post-cutting assembly 58.

[0038] Turning now to the details of the various assemblies, the stocksupply assembly 50 includes two laterally spaced brackets 62. Thebrackets 62 are each generally shaped like a sideways “U” and have twowalls 64 and 65 extending perpendicularly outward from a flat connectingwall 66. (See FIGS. 1 and 2.) For each bracket 62, the connecting wall66 is suitably secured to the downstream side of the frame end wall 44,such as with bolts. In the illustrated embodiment, the wall 64 isgenerally aligned with the frame base wall 43. However, the positioningof the brackets 62 is sometimes “dropped” so that the wall 64 issituated below (in the illustrated orientation) the base wall 43. Forexample, an intermediate portion of the connecting wall 66 may besituated at the same level as the base wall 43. Additionally oralternatively, a diagonal brace may be used which extends between theconnecting wall 66 and the wall 64.

[0039] Both of the walls 64 have open slots 70 in their distal end tocradle a supply rod 72 thereby defining a stock-dispensing device. Thesupply rod 72 is designed to extend relatively loosely through thehollow tube 29 of the stock roll 21. As the stock material 22 is pulledthrough the machine 20 by the feed assembly 54, the tube 29 will freelyrotate thereby dispensing the stock material 22. A pin (not shown) maybe provided through one or both ends of the supply rod 72 to limit orprevent rotation of the supply rod 72 itself. The slots 70 and thesupply rod 72 may be viewed as forming the stock-dispensing device ofthe stock supply assembly 50.

[0040] The other walls 65 of the U-brackets 62 extend from anintermediate portion of the frame end wall 44 and cooperate to mount aseparating device 74. The separating device 74 includes a pair ofmounting brackets 75 and three separating members 76, 77, and 78. One ofthe bar-mounting brackets 75 is secured, as by welding or bolting, tothe inner surface to one of the walls 65 at a distal portion (but notend) thereof. The other of the bar-mounting brackets 75 is secured tothe inner surface of the other of the walls 65 in the same manner sothat the brackets are laterally aligned. The opposite ends of theseparating members 76, 77 and 78 are non-rotatably attached to, and themembers extend between, the bar-mounting brackets 75. The number ofseparating members, namely three, corresponds to the number of paperlayers or webs of the stock material 22.

[0041] In the separating device 74, the separating members 76, 77 and 78are horizontally spaced relatively thin cylindrical separating barswhich extend in a linear transverse path in a direction perpendicular tothe upstream-downstream direction. The bars may comprise sleeves whichare rotatably mounted around rods attached to the walls 65 of thebrackets 62. Such sleeves are cylindrical and are sized to axiallyextend the entire transverse dimension (i.e. width) of the multi-plystock material 21. Also, each of the sleeves has a circularcross-sectional shape that is of the same diameter along its axialdimension. The sleeves and/or bars may all be of substantially the samediameter or, alternatively, the separating member 76 which engages theouter ply of the multi-ply stock material may be of a larger diameter.Details of a separating mechanism similar to the separating device 74are set forth in U.S. Pat. No. 4,750,896. (This patent is assigned toassignee of the present application and its entire disclosure is herebyincorporated by reference.)

[0042] The bracket walls 65 also cooperate to support a constant-entrydevice 80. The constant-entry device 80 comprises a rod 82 fixedlymounted to the distal ends of the bracket walls 65 and a sleeve 84,extending the distance between the walls 65, rotatably positioned aboutthe rod. Although not immediately apparent from the drawings, the sleeve84 may include side flanges to keep stock material properly centered.Details of a “roller member” or a “bar member” similar to theconstant-entry device 80 are set forth in U.S. Pat. No. 4,750,896.

[0043] After the stock material 22 is pulled from the stock roll 21 overthe constant-entry device 80 and through the separating device 74, it ispulled through the stock inlet opening 47 to the forming assembly 52.The forming assembly 52 includes a three-dimensional bar-like shapingmember 90 (or forming frame), a converging chute 92, a transverse guidestructure 93 and a guide tray 94. The stock material 22 travels betweenthe shaping member 90 and the frame base wall 43 until it reaches theguide tray 94. At this point, the transverse guide structure 93 and theguide tray 94 guide the stock material 22 longitudinally andtransversely into the converging chute 92. During this downstreamtravel, the forming assembly inwardly turns the lateral regions of thestock material 22 to form the lateral pillow-like portions 33. As thestrip emerges from the converging chute 92, the guide tray 94 guides thestrip into the feed assembly 54.

[0044] The illustrated shaping member 90 is a three-dimensional formingframe shown in detail in FIGS. 4-6. The shaping member 90 has a body 95and ribs 96 and 97 which are made of a bar-like material, such as metalrod. The body 95 is V-shaped (when viewed from the top) and comprises apair of leg portions 98 connected together by a rounded nose portion 99.(See FIG. 4.) These components of the body 95 are positioned in a commonplane which is titled in the downstream direction in the cushioningconversion machine 20. (See FIGS. 1 and 2.) The leg portions 98 and noseportion 99 are dimensioned so that the body 95 is approximately 14inches wide (at its point of maximum width) and approximately 24 incheslong.

[0045] The upstream rib 96 is generally U-shaped when viewed from thedownstream end and comprises a pair of side leg portions 100 connectedtogether by a bottom leg portion 101. (See FIG. 5.) The bottom legportion 101 is generally linear and extends laterally approximatelyeight inches. The side leg portions 100 are also generally linear andextend approximately 5¾ inches. The bottom end of each of the side legportions 100 is connected, via a rounded corner, to respective sides ofthe bottom leg portion 101. (See FIG. 5.) The upper ends of each of theside leg portions 100 is connected, via a rounded corner, to theupstream end of respective leg portions 98 of the body 95. (See FIG. 6.)In the illustrated embodiment, the body 95 and the rib 96 are formedfrom a continuous piece of rod-like material.

[0046] The downstream rib 97 is also generally U-shaped when viewed fromthe downstream end and comprises a pair of side leg portions 102connected together by a bottom leg portion 103. (See FIG. 5.) The bottomleg portion 103 is generally linear and extends approximately 3 inches.The side leg portions 102 are also generally linear and extendapproximately 2¾ inches. The bottom end of each of the side leg portions102 is connected, via a rounded corner, to respective sides of thebottom leg portion 103. (See FIG. 5.) The upper ends of each of the sideleg portions 102 are connected to aligned sections of the leg portions98 of the body 95, these sections being located approximately 13⅛ inchfrom the upstream rib 96. (See FIG. 6.)

[0047] The shaping member 90 may additionally include couplingcomponents 104 which are used in the mounting of the shaping member tothe machine's frame 36. In the illustrated embodiment, these connectingcomponents are tube-like receptacles attached to the center of thebottom leg portions 101 and 103 of the ribs 96 and 97. In the assembledmachine 20, mounting rods would be coupled to these components so thatthe shaping member 90 could be suspended in its correct orientation,such as from a strap (not shown) extending between the upstream anddownstream ends of the machine frame 36.

[0048] Alternatively, the forming assembly 52 may include the chuteand/or the shaping member disclosed in U.S. patent application Ser. No.08/487,179. (This application is assigned to the assignee of the presentapplication and its entire disclosure is hereby incorporated byreference.) Such a chute has an inlet end which is outwardly flared in atrumpeted fashion to facilitate passage of the stock material into theshaping chute. (The trumpet-like inlet may eliminate the need for thetransverse guide structure 93.) Such a shaping member is longitudinallyformed into a U-shape comprised of a first leg portion attached to a topwall of the chute and a second leg portion extending into the chutegenerally parallel with the bottom wall of the chute.

[0049] The guide tray 94 is directly mounted on the frame base wall 43;while the transverse guide structure 93 and the converging chute 92 aremounted on the guide tray 94. The guide tray 94 is trapezoidal in shape,as viewed in plan, having a broad upstream side 105 and a parallelnarrow downstream side 106. The broad side 105 is positioned downstreamof at least a portion of the shaping member 90. The narrow side 106 ispositioned adjacent the outlet opening in the frame end wall 46 andincludes a rectangular slot 107 to accommodate the feed assembly 54. Theguide tray 94 is not positioned parallel with the frame base wall 43,but rather slopes away (upwardly in FIGS. 1 and 2) from the frame basewall 43 to the feed assembly 54.

[0050] The converging chute 92 is mounted on the guide tray 94 upstreamof at least a portion of the shaping member 90 and downstream slightlyfrom the broad side 105 of the guide tray 94. The transverse guidestructure 93 is mounted on the guide tray 94 just upstream of theentrance mouth of the converging chute 92. The transverse guidestructure 93 includes rollers 108 rotatably mounted on a thin U-bracket109. The distal ends of the U-bracket 109 are secured to the guide tray94. Except for this mounting arrangement, the transverse guide structure93 is similar to the “rollers and wire frame” disclosed in U.S. Pat. No.4,750,896.

[0051] With the guide tray 94 and the transverse guide structure 93mounted in this manner, the stock material 22 travels over the guidetray 94, under the bottom leg portions 101 and 103 of the ribs 96 and 97of the shaping member 90, between the rollers 108 of the transverseguide structure 93, and into the converging chute 92.

[0052] The stock material 22 will emerge from the chute 92 as thecontinuous unconnected strip. The emerging strip is guided to the feedassembly 54 by the narrow downstream end 106 of the guide tray 94, whichextends from the outlet opening of the chute to the outlet opening inthe frame end wall 46. The feed assembly 54 includes rotating feedmembers between which the stock material 22 travels, specificallyloosely meshed horizontally arranged drive gear 124 and idler gear 126.When the gears 124 and 126 are turned the appropriate direction, whichin FIG. 2 would be clockwise for gear 124 and counterclockwise for gear126, the central band of the strip is grabbed by the gear teeth andpulled downstream through the nip of gears 124 and 126. This same“grabbing” motion caused by the meshing teeth on the opposed gears 124and 126 simultaneously compresses or “coins” the layers of the centralband together thereby connecting the same and forming the connectedstrip.

[0053] The drive gear 124 is positioned between the frame base wall 43and the guide tray 94 and projects through the rectangular slot 107 inthe guide tray 94. The gear 124 is fixedly mounted to a shaft 130 whichis rotatably mounted to the upstream side of the frame end wall 46 bybearing structures 131. A sprocket 132 at one end of the shaftaccommodates a chain 133 which connects the shaft 130 to a speed reducer136. The speed reducer 136 acts as an interface between the feedassembly 54 and the feed motor 55 for controlling the rate of “pulling”of the stock material 22 through the machine 20. As is best seen in FIG.1, the feed motor 55 and the speed reducer 136 are mounted on the framebase wall 43 at approximately the same level as the forming assembly 52.

[0054] The idler gear 126 is positioned on the opposite side of theguide tray 94 and is rotatably mounted on a shaft 140. Shaft brackets142 attached to an upstream side of the frame end wall 46 non-rotatablysupport the ends of the shaft 140 in spring-loaded slots 144. The slots144 allow the shaft 140, and therefore the idler gear 126, to “float”relative to the drive gear 124 thereby creating an automatic adjustmentsystem for the feed assembly 54.

[0055] Alternatively, the automatic adjustment system for the feedassembly 54 could be of the type disclosed in U.S. patent applicationSer. No. 08/487,179. In such an adjustment system, first and second tiemembers would be movably connected to the shaft 140 and would extendtransversely with respect to the shaft 140. Each of the tie memberswould have one end in fixed transverse position relative to themachine's housing 36 and an adjustable stop which is selectivelyadjustable towards and away from the shaft 140. A spring member would beinterposed between the shaft 140 and the adjustable stop to resilientlybias the shaft 140 towards the shaft 130. In this manner, the pinchforce applied by the rotating feed members 124 and 126 could be adjustedwithout changing a minimum set distance between the shafts 130 and 140.

[0056] Additionally or alternatively, the rotating feed members 124 and126 may be of the type contained in the stitching assembly disclosed inU.S. patent application Ser. No. 08/607,607. (This application isassigned to the assignee of the present application and its entiredisclosure is hereby incorporated by reference.) In such a stitchingassembly, the first rotating feed member would have a plurality ofradially outwardly extending projections around its circumference andthe projections would have axially spaced apart segments defining arecess therebetween. The second rotating feed member would have axialpunch segments which each include a peripheral edge portion for receiptinto the first member's recesses. The peripheral edge portions wouldhave opposite corners which are cooperative with the first member'sprojections to cut a row of slits in the overlapped portions of thestock material to interlocking these overlapped portions.

[0057] In any event, the feed assembly 54 transforms the unconnectedstrip into the connected strip and this strip travels through the outletopening in the frame end wall 46. The connected strip is then cut by thecutting assembly 56 into cut sections 32 of the desired length. Thecutting assembly 56 may be of any suitable type, such as the typesdisclosed in U.S. Pat. No. 5,123,899, the type disclosed in U.S. patentapplication Ser. No. 08/110,349, and/or the type disclosed in U.S.patent application Ser. No. 08/188,305. (This patent and theseapplications are assigned to the assignee of the present invention andtheir entire disclosures are hereby incorporated by reference.) However,whatever type of cutting or severing assembly is used, the connectedstrip is divided into cut sections 32 of the desired length and thesecut sections 32 then travel downstream to the post cutting assembly 58.A cut section 32 emerging from the post-cutting assembly 58 may bedirected to a desired packing location, the conversion of stock material22 to cut sections 32 of relatively low density pad-like cushioningdunnage product now being complete.

[0058] Thus, the cushioning conversion machine 20 may be viewed ascomprising a conversion assembly 30 (i.e., the forming assembly 52, thefeed assembly 54, etc.) which converts multi-ply stock material 22 intoa three-dimensional cushioning product 32 and a stock supply assembly 50which supplies the multi-ply stock material to the conversion assembly.The conversion assembly includes the forming assembly 52 which inwardlyturns the lateral regions of the stock material 22 as it travelsdownstream therethrough.

[0059] Referring briefly back to the stock supply assembly 50, itincludes the separating device 74 which separates the individual plies24, 26 and 28 of the stock material 22 upstream of the forming assembly52. As is best seen in FIGS. 1 and 2, the inwardly turning of the stockmaterial begins just downstream of the separating device 74. As wasnoted above, the separating members 76, 77 and 78 of the separatingdevice 74 extend between the stock supply brackets 62 and extend in alinear path in a direction perpendicular to the upstream-downstreamdirection. As such, the plies 24, 26 and 28 of the stock material 22traveling over the separating members 76, 77 and 78 are forced to followa straight transverse path and are prevented from inwardly turning inthe same direction as the forming assembly 52. Accordingly, in the stocksupply assembly 50, the lateral regions of the stock material mustabruptly begin their inwardly turning after engaging the separatingmembers. This abruptness may effect the conversion process by, forexample, resulting in excessive tension in the lateral regions whichsometimes leads to ripping or tearing of the paper.

[0060] Turning now to FIG. 7, a stock supply assembly 350 according tothe present invention is shown. The stock supply assembly 350 may beincorporated into a cushioning conversion machine, such as thecushioning conversion machine 20 described above or any other cushioningconversion machine or method which falls within the scope of the claims.As is explained in more detail below, the stock supply assembly 350allows a more gradual transition between the supply of the stockmaterial to the machine's conversion assembly and the inward turning oflateral edges by the conversion assembly. Such an arrangement isbelieved to reduce edge-tension in the stock material and/or otherwiseenhance the conversion process.

[0061] The stock supply assembly 350, like the stock supply assembly 50,discussed above, includes two laterally spaced brackets 362 which areessentially the same as the brackets 62. Thus, the brackets 362 have twolegs 364 and 365 extending perpendicularly outward from a flatconnecting base wall 366. The legs 364 have open slots 370 in theirdistal ends which cradle a supply rod 372 such as the supply rod 372discussed above which is designed to extend relatively loosely throughthe hollow tube 29 of the stock roll 21 whereby as the stock material 22is pulled through the machine 20 by feed assembly 54, the tube 29 willfreely rotate thereby dispensing the stock material 22. The legs 364 maybe replaced with other bracket portions if desired, such as themulti-position stock roll support bracket shown in U.S. ProvisionalApplication No. 60/051,355, file Jun. 30, 1997 and entitled “CushioningConversion Machine/method And Packaging System.” (This application isassigned to the assignee of the present application and its entiredisclosure is hereby incorporated by reference.) In any event, the openslots 370 and the supply rod 372 may be viewed as forming thestock-dispensing device of the stock supply assembly 350.

[0062] The other legs 365 of the U-brackets 362 extend from anintermediate portion of the frame end wall 44 and cooperate to mount aseparating device, indicated generally at 374. The separating device 374includes three transversely extending members 376, 377 and 378. Thenumber of separating members, namely three, corresponds to the number ofpaper layers or webs or plies of the stock material 22. The separatingdevice 374 separates the layers 24, 26 and 28 of paper prior to theirpassing to the forming assembly 52.

[0063] The bracket legs 365 also cooperate to support a constant-entrymember 380 which is rotatably mounted on the distal ends of the legs.The member 380 may be of essentially the same construction and performessentially the same function as the constant entry bar 80 discussedabove. Particularly, the constant-entry member 380 provides anon-varying point of entry for the stock material 22 into the separatingdevice 374 and forming assembly 52, regardless of the diameter of thestock roll 21. The member 380 may also be other than cylindrical inshape and may have a bowed or convex shape. That is, the constant entrymember may progressively decrease in diameter from the middle thereof toits ends, preferably in a manner that provides a rounded or convexlycurved outer surface similar to what is shown in FIG. 10. In accordancewith the invention, such a rounded constant entry member, preferably aroller, may be incorporated into a cushioning conversion machine likethat shown in FIGS. 1-3 in combination with or separately from the othernovel features of the present invention.

[0064] Although not specifically shown in the drawings, the stock supplyassembly 350 may additionally comprise a dancer roll, such as a gravityor spring biased dancer roll, which defines the path of the stockmaterial from the stock-dispensing device to the constant entry roller380.

[0065] The outer separating member 376 includes end portions 400 and acentral portion 402 extending therebetween. The end portions 400 areinwardly tapered relative to the central portion 402 towards therespective ends of the member 376. The inwardly tapered lateral endportions 400 of the member 376 are positioned to engage the ends of thelateral portions of the outer ply 24 of the stock material. In thismanner, the outer ply 24 of stock material engaging the outer separatingmember 376 is not forced to follow a straight transverse path. Instead,the lateral portions of the outer ply 24 of stock material are inwardlyurged in the same direction as the forming assembly inwardly turns thelateral edges of the stock material. This allows a gradual, rather thanabrupt, transition between separating device 374 and the formingassembly 52 thereby reducing the chance of excessive edge-tension and/orotherwise enhancing the conversion process.

[0066] The end portions 400 preferably each occupy between 2%-6% of theentire axial length of the separating member 376, with the centralportion 402 occupying the other 96%-88% of the axial length of themember 376. More preferably, the end portions 400 each occupy 3%-5%, andmore preferably approximately 4% of the member's axial length. Thus,when the cushioning conversion machine is designed to convert stockmaterial which is approximately 30 inches wide, the end portions 400will preferably each occupy the outer 1.2 inches of the member 376, withthe center portion 402 occupying the center 27.6 inches of the member376.

[0067] The illustrated outer separating member 376 comprises a rod 404,a sleeve 406, and a pair of end caps 408 connected to each end of thesleeve 406. The rod 404 is non-rotatably mounted between the bracketlegs 376 and the sleeve 406 and caps 408 are rotatably mounted about therod 404. The sleeve 406 forms the center portion 402 of the separatingmember 376 and is preferably cylindrical with a constant circular radialcross-sectional shape along its axial dimension.

[0068] The caps 408 each include a head 410 and a plug 412 connected tothe head 410. The head 410 forms the inwardly tapering end portions 400of the separating member 376. Preferably, the head 410 has a circularradial cross-section shape which decreases in size along its axialdimension and an axial cross-sectional shape resembling a top-truncatedparabola. (FIG. 8.) The plugs 412 extend from the axially inner end ofthe respective head 410 and are sized for tight inserted receipt intothe ends of the sleeve 406 whereby the sleeve 406 will not rotaterelative to the end caps 408. The end caps 408 are preferably made ofsuitable material, such as plastic, so that they form a bearing surfacerelative to the rod 404.

[0069] The outer separating member 376 may additionally include a pairof springs 414 positioned around the rod 404 on opposite sides of theend caps 408, to provided biased transverse centering of the sleeve 406and the caps 408 on the rod 404.

[0070] Another outer separating member 476 is shown in FIG. 10, whichincludes inwardly tapered end portions 490 and a central portion 492extending therebetween. The separating member 476 comprises a rod 494which is non-rotatably mounted between the bracket legs 365 and a sleeve496 which is mounted for rotation around the rod 494. The sleeve 496forms the central portion 492 of the member and also the inwardlytapered lateral end portions 490 of the member. In the illustratedembodiment, the sleeve 496 is cylindrical and has a circular radialcross-sectional shape which changes size along its axial dimension. Theradial cross-sectional size of the sleeve 496 preferably changesgradually along the central portion 492 of the separating member andmore dramatically along the lateral end portions 492 of the separatingmember 476. Although not specifically shown in the drawings, the outerseparating member 476 may additionally include a pair of springs 614positioned around the rod 494 on opposite sides of the sleeve 496, toprovided biased transverse centering of the sleeve 496.

[0071] The intermediate separating member 377 is positioned to engagethe intermediate ply 26 of the multi-ply stock material and ispreferably of the same construction as the intermediate member 77discussed above in connection with the separating device 76 of themachine 20. Thus, the intermediate member 376 includes a sleeve or rodhaving the same diameter along its entire axial length whereby it doesnot include inwardly tapered lateral end portions. This more economicalnon-tapered construction is preferred since the intermediate ply 26experiences less excessive edge-tension problems than the outer ply 24and/or the inner ply 28. The cross-sectional area (or diameter) of theintermediate member 377 is preferably less than the cross-sectional areaof the central portion 402 of the outer member 376 or the centralportion 502 of the outer member 476.

[0072] The inner separating member 378 is positioned to engage the innerply 28 of the multi-ply stock material. The member 378 is preferably ofthe same general construction as the outer separating member 377 or theouter separating member 504. In this manner, the inner ply 28 of stockmaterial engaging the inner separating member 378 is not forced tofollow a straight transverse path. Instead, the lateral portions of theinner ply 28 are inwardly urged in the same direction as the formingassembly 52 inwardly turns the lateral edges of the stock material. Thisallows a gradual, rather than abrupt, transition between separatingdevice 376 and the forming assembly 52 thereby reducing the chance ofexcessive edge-tension and/or otherwise enhancing the conversionprocess.

[0073] Preferably, the overall axial length of the inner separatingmember 378 is not the same as the overall axial length of the outerseparating member 376. More preferably, the inner separating member 378is slightly longer than the outer separating member, in the range of 1½%to 5% and more preferably in the range of 2.6%. This is lengtharrangement is preferred since the inner separating member 378 engagesthe inner ply 28 which becomes the outer ply in the cushioning product32 and thus must envelope or encapsulate the other plies 24 and 26.

[0074] Thus, in the preferred embodiment, two of the separating members,namely the inner and outer separating members 376 and 378, include theinwardly tapering end portions. However, a stock supply assembly whereinonly the outer separating member includes the inwardly tapering endportions, wherein only the inner separating member includes the inwardlytapering end portions, or any other arrangement wherein at least one ofthe separating members includes the inwardly tapering end portions ispossible with, and contemplated by, the present invention. Moreover, theincorporation of such a transversely extending member into a cushioningconversion machine which does not include a separating device ispossible with, and contemplated by, the present invention.

[0075] When a cushioning conversion machine incorporating a stock supplyassembly 350 is used, the resulting method will comprise the steps ofthe steps of supplying a multi-ply stock material and converting thestock material into a three dimensional cushioning product. Theconverting step includes the step of inwardly turning lateral portionsof the stock material as the stock material travels in a downstreamdirection. The supplying step includes the steps of dispensing the stockmaterial from a continuous sheet of multi-ply stock material andengaging at least one ply of the dispensed stock material with atransversely extending member which inwardly urges the lateral endportions of the at least one ply in the same direction as the inwardlyturning step of the converting step.

[0076] One may now appreciate that the present invention provides acushioning conversion machine and method in which the stock supplyassembly or step allows a more gradual transition between the supply ofthe stock material to the machine's conversion assembly and the inwardturning of lateral edges by the conversion assembly.

[0077] Turning now to FIG. 11, another embodiment of stock supplyassembly 550 according to the present invention is shown. The stocksupply assembly 550 may be incorporated into a cushioning conversionmachine, such as the cushioning conversion machine 20 described above orany other cushioning conversion machine or method which falls within thescope of the claims. As is explained in more detail below, the stocksupply assembly 550 allows a more gradual transition between the supplyof the stock material to the machine's conversion assembly and theinward turning of lateral regions by the conversion assembly. Such anarrangement is believed to reduce tension in the lateral regions of thestock material and/or otherwise enhance the conversion process.

[0078] The stock supply assembly 550, like the stock supply assembly 50,discussed above, includes two laterally spaced brackets 562 which areessentially the same as the brackets 62. Thus, the brackets 562 have twowalls 564 and 565 extending perpendicularly outward from a flatconnecting wall 566. For each bracket 562, the connecting wall 566 issuitably secured to the downstream side of the frame end wall 44, suchas with bolts. In the illustrated embodiment, the positioning of thebrackets 562 is “dropped” when compared to the brackets 62 of the stocksupply assembly 50, so that the wall 564 is situated below (in theillustrated orientation) the base wall 43 and a center region of theconnecting wall 566 is situated at the same level as the base wall 43. Adiagonal brace 567 is also used which extends between the connectingwall 566 and the wall 564.

[0079] The walls 564 have open slots 570 in their distal ends whichcradle a supply rod 572 such as the supply rod 72 discussed above whichis designed to extend relatively loosely through the hollow tube 29 ofthe stock roll 21 whereby as the stock material 22 is pulled through themachine 20 by feed assembly 54, the tube 29 will freely rotate therebydispensing the stock material 22. The walls 564 may be replaced withother bracket portions if desired, such as the multi-position stock rollsupport bracket shown in U.S. Provisional Application No. 60/051,355,file Jun. 30, 1997 and entitled “Cushioning Conversion Machine/methodand Packaging System.” (This application is assigned to the assignee ofthe present application and its entire disclosure is hereby incorporatedby reference.) In any event, the open slots 570 and the supply rod 572may be viewed as forming the stock-dispensing device of the stock supplyassembly 550.

[0080] The other walls 565 of the brackets 562 are similar to the walls65 of the brackets 62 discussed above. However, they additionallyinclude a flat upturned (in the illustrated orientation) tail 573 attheir distal ends. Preferably the tail 573 is formed in one piece withthe other portions of the walls 565 and is flush with the verticalportion of the angle iron forming these other portions.

[0081] The walls 565 cooperate to mount a separating device 574. Theseparating device 574 includes a pair of mounting brackets 575 and threeseparating members 576, 577 and 578. One of the mounting brackets 575 issecured, as by welding or bolting, to the inner surface to one of thewalls 565 at a distal portion (but not end) thereof. The other of themounting brackets 575 is secured to the inner surface of the other ofthe walls 565 in the same manner so that the brackets 575 are laterallyaligned. In a retrofit situation, the mounting brackets 575 may bemounted to the brackets 75 of the separator device 74 (once theseparator rods 76-78 have been removed). In either case, the oppositeends of the separating members 576, 577 and 578 are non-rotatablyattached to, and the members extend between, the mounting brackets 575.The number of separating members, namely three, corresponds to thenumber of paper layers or webs of the stock material 22.

[0082] The bracket walls 565 (and specifically the tails 573) alsocooperate to support a constant-entry device 580 which is rotatablymounted on the distal ends of the walls. When using the separatingdevice 574, the constant-entry device 80 discussed above may be used,but tearing may occur upstream of the separating device 574. For thisreason, it is preferred to use the constant entry device 580 which isdiscussed in more detail below.

[0083] Turning now to FIGS. 12 and 13, the separating device 574 isshown in detail isolated from the other components of the stock supplyassembly 550. The separating members 576, 577 and 578 are preferablycylindrical in shape and are also preferably of the same cross-sectionaldiameter. A suitable diameter for the separating members 576, 577 and578 would be, for example, {fraction (1/4)} inch. The members may bemade of any suitable metal or plastic which will not unduly interferewith the travel of the stock material through the separating device 574.Additionally or alternatively (but not specifically shown in thedrawings), some or all of the separating members 576, 577 and 578 may beprovided with a series of rings to provide a rotating sleevearrangement.

[0084] In accordance with the present invention, the separating members576, 577 and 578 do not follow a transverse linear path between themounting brackets 575, but instead have a bowed or curved configuration.The direction of concavity/convexity of the members corresponds to thevertical component (in the illustrated orientation) of the travel of thelateral regions of the stock material as they are being inwardly turnedby the forming assembly 52. In the illustrated embodiment, the lateralregions of the stock material are moved upwardly and inwardly by theforming assembly 52 during the conversion process. Thus, the separatingmembers 576, 577 and 578 are concave when viewed from the upstream endof the cushioning conversion machine 20.

[0085] The magnitude of the concavity/convexity of each of the memberscorresponds to amount of inward turning of the lateral regions of thestock material in the forming assembly 52 and the distance between theforming assembly 52 and the separating device 574. Specifically, themagnitude is such that there will be a gradual transition between thecurvature of the stock material from the separating device 574 to theforming assembly 52 and is such that tension is evenly distributedthough the full width of the paper. For example, in a cushioningconversion machine wherein twenty-seven to thirty inch wide stockmaterial is formed into a strip which is approximately eight to nineinches wide, the radius of curvature would preferably be betweentwenty-six and thirty-four inches, more preferably between twenty-sevenand thirty-three inches, and even more preferably between twenty-eightand thirty-two inches.

[0086] In the preferred and illustrated embodiment of the separatingdevice 574, the radius of the curvature varies between the separatingmembers 576, 577 and 578. Specifically, the radius of curvatureincreases from the separating member 576 which engages the ply 24forming the innermost ply of the cushioning product 32 to the separatingmember 578 which engages the ply 28 forming the outermost ply of thecushioning product 32. Also in the preferred and illustrated embodimentof the separating device 574, the separating members 576, 577 and 578are concentric (i.e., have the same center of curvature) whereby theyform a “bull's-eye” arrangement. For example, the separating members576, 577, and 578 could have concentric radii of curvature of28{fraction (15/16)} inches, 30 inches, and 31{fraction (1/16)} inches,respectively. In such an arrangement, the ends of the separating member576 would be attached 1¼ inches above the separating member 577 on thebrackets 575, and the separating member 577 would be attached 1⅛ inchesabove the separating member 578.

[0087] Other types of separating members are possible with, andcontemplated by, the present invention. For example, the bowedseparating members could have non-concentric radii of curvature therebycreating an eccentric, rather than bull's eye, arrangement. Additionallyor alternatively, the bowed configuration of a separating member couldbe accomplished by sloped substantially linear end sections attached toa substantially linear central section. It is noted that the curved andconcentric separating members 576, 577 and 578 have been found to reducetearing significantly better than these alternative designs when usedwith a conversion assembly such as the conversion assembly 30. However,these alternate designs may be acceptable and perhaps preferred withother types of conversion assemblies.

[0088] As was indicated above, the number of separating members, namelythree, corresponds to the number of paper layers or webs of the stockmaterial 22. If it is preferred to use a stock material with more orless plies, the number of separating members may be varied, or if it isdesired for some reason to separate only some of the plies of the stockmaterial, the number of separating members may be modified accordingly.Moreover, the incorporation of such a single member having this type ofcurved construction into a cushioning conversion machine which does notinclude a separating device is possible with, and contemplated by, thepresent invention. For example, with a multi-ply stock material, all ofthe plies could pass together pass over or under one such member.Alternatively, if single ply stock material is being converted, only onemember would be necessary.

[0089] As was also indicated above, when using the separating device574, it is preferred to use a constant-entry device 580 according to thepresent invention, as opposed to the constant entry device 80.

[0090] Referring briefly back to the constant-entry device 80, itprovides a non-varying point of entry for the stock material 22 into theseparating device 74 and forming assembly 52, regardless of the diameterof the stock roll 21. Thus, when a different diameter roll is usedand/or as dispensation of the stock material 22 from the roll 21decreases its diameter, the point of entry of the stock material 22 intothe separating device 74 remains constant. This consistency is believedto facilitate the production of uniform cushioning product.

[0091] As the stock material being drawn into the conversion assembly 30from the stock roll 21, it will exert a downward force on the sleeve (orguide roller) 84 of the constant-entry device 80 by reason of thepulling force needed to rotate the stock roll 21. The sleeve 84 ispositioned at the optimum entry point for the stock material when it issubjected to normal downward forces associated with steady stateoperation of the machine throughout the normal diameter range of thestock roll 21. However, during start-up, where the stock roll must beaccelerated from a rest condition to a rotational speed dictated by thefeed rate of the feeding assembly 54, the pulling force and consequentlythe tension of the stock material may increase to a point that causestearing of the paper.

[0092] The constant-entry device 580 also provides a constant point ofentry for the stock material when it is subjected to normal downwardforces associated with steady state operation of the machine throughoutthe normal diameter range of the stock roll 21. However, theconstant-entry device 580 additionally functions temporarily as a forcedampening device during a high tension situation, such as during astart-up situation when it is necessary to overcome the startingmomentum of the stock roll. Once the high tension is relieved, theconstant-entry device 580 automatically returns to its normal operatingposition.

[0093] The constant entry device 580 of the stock supply assembly 550,like the constant entry device 80 of the stock supply assembly 50,comprises a rod 582 and a sleeve 584. The sleeve 584 forms a guideroller extending the distance between the walls 565 and rotatablypositioned about the rod. However, the rod 582 of the constant-entrydevice 580 is not fixedly mounted to bracket walls 565. Instead, in theconstant-entry device 580, the rods 582 are resiliently supported andguide by spring-loaded mechanisms 585 which function as “shockabsorbers” or “dampers” in the event of excessive tension.

[0094] As is shown in FIG. 11, each of the spring-loaded mechanisms 585are secured to one of the tails 573 of the bracket walls 565. Eachspring-loaded mechanism 585 includes a tubular housing 586, shownisolated and in more detail in FIG. 10. The tubular housing 586 includesan elongated guide slot 587 having a width sufficient to receive theends of the rod 582 and having a length corresponding to the desiredrange of vertical movement. The tubular housing 586 also includes anopening 588 below the slot 587 for securing the housing to the wallbrackets 655 by a suitable fastening device.

[0095] As is shown schematically in FIG. 11, a spring 589 is providedwithin the housing 586 which resiliently supports the end of the rod582. In this manner, as the stock material 22 passes over the sleeve584, the rod 582 may resiliently float within the slot 587 within acertain range. Preferably, the springs 589 are pre-loaded so as to holdthe guide roller as its normal operating position (its uppermostposition in FIG. 11) when the guide roller is subjected to normaldownward forces associated with steady state operation of the machinethroughout the normal diameter range of the stock roll 21. However,during start-up, where the stock roll must be accelerated from a restcondition to a rotational speed dictated by the feed rate of the feedingassembly 54, the springs 589 yield and release tension on the stockmaterial 21. Once the high-tension situation has be resolved and thedownward force on the stock material is normalized, the spring 589 willbias the rod 582 to its upper position within the slot 587.

[0096] The travel range that the spring mechanism 589 provides for therod 582 should be great enough to accommodate anticipated high tensionsituations (such as overcoming starting momentum of the paper roll) yetlimited enough to ensure adequate conversion of the stock material. Itshould perhaps be noted that constant entry device 580 functionsprimarily temporarily in contrast to a dancer roll which continuouslyadjusts its position in response to differential changes in force ortension. In the illustrated embodiment, the travel range is preferablybetween 2½ inches and 4½ inches. To accomplish this travel range, thespring 589 may be a coiled music wire having a compression rate ofbetween 3 and 8 lbs/inch and more preferably about 5 lbs/inch.

[0097] In certain conversion machines, the constant-entry device 580 maybe used without separator members having the concave configuration ofthe members 576, 577 and 578. However, it is not preferred to use thisdevice 580 with the cushioning conversion machine 20 incorporating theseparator members 76, 77 and 78, as it may increase tension and/ortearing problems. Nonetheless, it is contemplated that the constantentry device 580 of the present invention may be used with cushioningconversion machines with differently designed separator devices and/orwithout separator devices.

[0098] When the separator device 574 and the constant entry device 580are used with the forming assembly 52, a smaller cushioning product isproduced than that produced with this separator device 74 and constantentry device 80. This smaller, more compact cushioning product isbelieved to be adequate, and possibly preferred, in certain packagingsituations. However, to increase the size of the pad, the shaping member90 of the forming assembly 52 may be replaced with a shaping member 590according to the present invention.

[0099] Referring briefly back to the shaping member 90, it is positionedpartially within the chute 92. The stock material 22 travels around theshaping member 90 and through the chute 92 as it passes through theforming assembly 52. As the stock material 22 is passing through theforming assembly 52, the lateral regions of the stock material 22 areinwardly turned over the leg portions 98 of the V-shaped body 95 of theshaping member. As such, the leg portions 98 of the body 95 may beviewed as forming a turning perimeter for the lateral regions of thestock material 22. Since these leg portions 98 are positioned in acommon plane, all of the portions of the turning perimeter of theshaping member 90 are positioned in a common plane. Thus, in the shapingmember 90, there are no protrusions which project beyond the co-planarportions (the legs 98) of the turning perimeter.

[0100] Also as the stock material 22 is passing through the formingassembly, the bottom wall 98 of the rib 96, the bottom wall 100 of therib 97, and the nose portion 99 of the body 95 hold the central regionsof the stock material 22 as its lateral regions are inwardly turned. Inthe shaping member 90, the rib bottom walls 98 and 100 and the noseportion 99 are situated in the same plane in a triangular configuration.(See FIG. 10.) Particularly, when a line is drawn from one of the endsof the bottom leg portion 101 of the upstream rib 96 to the vertex ofthe nose portion 99 of the body 95, it passes through the correspondingend of the bottom leg portion 103 of the downstream rib 96. When a lineis drawn from the other end of the bottom leg portion 101 of theupstream rib 96 to the vertex of the nose portion 99 of the body, itpasses through the other end of the bottom leg portion 103 of thedownstream rib. In this manner, the portions 99, 98 and 100 of theshaping member form a “holding surface” surface which holds the centralregions of the stock material to increase the “height” or “fluff” of thecushioning product. Thus, all portions of this holding surface areco-planar and the holding surface does not include any projections whichproject beyond this common plane.

[0101] As was just noted above, the nose portion 99 of the body 95 ofthe shaping member 90 is the downstream edge of the shaping member 90.The nose portion 99 is essentially a “rounded corner” or “curved vertex”between the side leg portions 98 of the shaping member 90. As such, thenose portion 99 does not include a transverse linear component.

[0102] The shaping member 590 according to the present invention isshown isolated and in detail in FIGS. 15-17. In the illustratedembodiment, the shaping member 590 is made by modifying or retrofittingthe shaping member 90 discussed above. However, as explained below, theshaping member 590 may also be formed independently rather than as aretrofit.

[0103] The shaping member 590 is a three-dimensional forming framehaving a body 595 and ribs 596 and 597. The body 595 is substantiallysimilar to the body member 95 of the shaping member 90 and thus isV-shaped (when viewed from the top) and comprises a pair of leg portions598 connected together by a nose portion 599. (See FIG. 15.) Whenincorporated into the cushioning conversion machine 20, these componentsof the body 595 would be positioned in a common plane which is tilted inthe downstream direction. The leg portions 598 are the same as the legportions 98 of the shaping member 90 whereby the body 595 isapproximately 24 inches long. The width of the nose portion 599 isincreased by two inches when compared to the nose portion 99 of theshaping member 80. The increase in width of the nose portion 599 resultsin it having more of a flattened U-shape as opposed to the roundedcorner shape of the nose portion 99 of the shaping member 90. Also, theincrease in width of the nose portion 599 results in the body 595 beingapproximately sixteen inches wide, as compared to the body 95 which isapproximately fourteen inches wide.

[0104] The upstream rib 596, which is also increased width by twoinches, is generally U-shaped when viewed from the downstream end andcomprise a pair of side leg portions 600 connected together by a bottomleg portion 601. (See FIG. 16.) The side leg portions 600 areessentially the same as the side leg portions 100 of the shaping member90 and thus are generally linear and extend approximately 5¾ inches. Thebottom leg portion 601 is similar to the bottom leg portion 101 of theshaping member 90 except that its width is increased by the noted twoinches whereby it extends approximately ten inches as compared to thebottom leg portion 101 which extends eight inches. As in the shapingmember 90, the upper ends of each of the side leg portions 600 isconnected, via a rounded corner, to the upstream end of respective legportions 598 of the body 595. (See FIG. 17.)

[0105] The downstream rib 597 is also generally U-shaped when viewedfrom the downstream end and comprises a pair of side leg portions 602connected together by a bottom leg portion 603. (See FIG. 16.) The sideleg portions 602 are essentially the same as the side leg portions 102of the shaping member 90 and thus are generally linear and extendapproximately 2¾ inches. The bottom leg portion 603 is essentially thesame as the bottom leg portion 103 of the shaping member 90 except thatits width is increased by two inches whereby it extends approximatelyfive inches as compared to the bottom leg portion 101 which extendsthree inches. The bottom end of each of the side leg portions 602 isconnected, via a rounded corner, to respective sides of the bottom legportion 603. (See FIG. 16.) The upper ends of each of the side legportions 602 is connected to aligned sections of the leg portions 598 ofthe body 595, these sections being approximately 13⅛ inch from itsupstream end. (See FIG. 17.)

[0106] In the illustrated retrofitted embodiment, the increase in widthof the nose portion 599 is accomplished by a two inch extension piececentrally inserted therein. For example, the nose portion 599 couldcentrally cut and then the extension piece sandwiched between the cutsand secured in place by welding. Likewise, the increase in width of thebottom leg portions 601 and 603 of the ribs 596 and 597 is accomplishedby two inch extension pieces centrally inserted therein. However, if theshaping member 590 is not being made as retrofit, the portions 595, 596and 597 could be formed in the same manner as the portions 95, 96 and 97of the shaping member 90 to obtain the increase in width.

[0107] The shaping member 590 may additionally include couplingcomponents 604 of essentially the same construction, and for the samepurpose as, the coupling components 104 of the shaping member 90.

[0108] The shaping member 590 additionally includes a pair of wingportions 610. In the illustrated embodiment, the wing portions 610 aremade of the same bar-like material as the rest of the shaping member590. Each wing portion 610 is generally L-shaped having a long legportion 612 and a shorter leg portion 614 extending from one endthereof. The union between the leg portions 612 and 614 is a roundedcorner forming a slightly less than perpendicular (i.e., 75° to 80°)angle. The leg portion 612 extends approximately 9 inches and the legportion 614 extends approximately 1½ inches.

[0109] The wing portions 610 are attached to the top of the side legportions 598 of the body 595 and extend upwardly therefrom. Morespecifically, the distal end of the leg portion 612 of one of the wingportions 610 is secured to one of the side leg portions 598 justdownstream of the connection point for the downstream ribs 597 and 610.To this end, the leg portion 612 preferably has a contoured edge so thatit can lay substantially flush against the top surface of the legportion 598. (See FIGS. 15 and 17.) The distal end of the leg portion614 of this wing portion is secured to this same leg portion 598 justupstream of the corner forming the transition to the nose portion 599.Thus, in the modified forming assembly 52, the wing portions 610 will bepositioned within the chute 92.

[0110] The shaping member 590 further includes a downstream rib 620which comprises a pair of side leg portions 622 and a bottom leg portion623 extending therebetween. (See FIG. 16.) The bottom leg portion 623 isgenerally linear and extends approximately 6 inches, as compared to thebottom leg portion 603 of the rib 597 which extends approximately fiveinches. The side leg portions 622 extend approximately 3{fraction(3/16)} inches, as compared to the side leg portions 602 of the rib 597which extend 2¾ inches.

[0111] The bottom end of each of the side leg portions 622 is connected,via a rounded corner, to respective sides of the bottom leg portion 623.(See FIG. 16.) It may be noted that while the side leg portions 602 ofthe rib 597 slant inwardly to meet the bottom leg portion 603, the sideleg portions 622 of the rib 620 extend generally perpendicularly fromthe plane of the body 595. The upper ends of each of the side legportions 622 is connected to aligned sections of the leg portions 598 ofthe body 595, these sections being approximately 13⅛ inch from itsupstream end and thus at the same point as the side leg portions 602 ofthe rib 597 are connected to the body. (See FIG. 17.)

[0112] As the stock material 22 is passing through the forming assembly52, the lateral regions of the stock material 22 are inwardly turnedover the upper portions of the shaping member 590, particularly the legportions 598 of the V-shaped body 595 and the wing portions 610. Assuch, the leg portions 598 and the wing portions 610 may be viewed asforming a turning perimeter for the lateral regions of the stockmaterial 22. Although the leg portions 598 of the body 595 arepositioned in a common plane, the wing portions 610 project beyond thisplane. In this manner, the wing portions 610 form protrusions whichproject beyond (and more particularly extend perpendicularly from) theco-planar portions of the turning perimeter. These protrusions formed bythe wing portions 610 results in an increase in the loft of thecushioning product produced by the cushioning conversion machine 20.Also, the geometry of the wing portions 610 results in the protrusionincreasing in the downstream direction, in contrast to the overallgeometry of the shaping member 590 which decreases in the downstreamdirection.

[0113] In the shaping member 590, the bottom leg portion 601 of the rib596, the bottom leg portion 623 of the rib 620, and the nose portion 599of the body 595 hold the central regions of the stock material 22 as itslateral regions are inwardly turned. In this manner, the portions 601,623 and 599 form a “holding surface” surface which holds the centralregions of the stock material while its lateral regions are inwardlyturned.

[0114] In the shaping member 590, the bottom leg portion 601 of the rib596, the bottom leg portion 603 of the rib 596 and the nose portion 599are situated in the same plane in a triangular configuration. (See FIG.16.) Particularly, when a line is drawn from one of the ends of thebottom leg portion 601 of the upstream rib 596 to the vertex of the noseportion 599 of the body 595, it passes through the corresponding end ofthe bottom leg portion 603 of the downstream rib 596. When a line isdrawn from the other end of the bottom leg portion 601 of the upstreamrib 596 to the vertex of the nose portion 599 of the body, it passesthrough the other end of the bottom leg portion 603 of the downstreamrib. However, the bottom leg portion 603 of the rib 596 extends belowthis line whereby the bottom leg portion 623 of the rib 596 forms aprojection which project beyond a plane extending from the downstreamedge of the surface (the leg portion 601) to the upstream edge of thesurface (the nose portion 599). Instead, the bottom leg portion 623extends below this plane thereby forcing the central regions of thestock material 22 to travel an increased distance around the rib 620.This increased travel path at an intermediate region of the shapingmember 590 for the central regions of the stock material results in lessstock material being inwardly turned to form the central portion of thecushioning product.

[0115] Thus, the rib 620 extends laterally beyond and also extends belowthe rib 597 thereby “overshadowing” or “superseding” the rib 597 wherebyit does not contact the stock material 22 during the forming process.For this reason, if the shaping member 590 was not being made as aretrofit to the shaping member 90, the rib 597 could be eliminated fromshaping member 590. In such a case, the coupling component 104 couldinstead be attached to a central region of the rib 610.

[0116] The nose portion 599 of the body 595 forms the downstream edge ofthe shaping member 590. As was explained above, the nose portion 599 ofthe body 595 of the shaping member 590 is transversely extended 2 incheswhen compared to the nose portion 99 of the body 95 of the shapingmember 90. The nose portion 99 of the shaping member 90 is essentially a“rounded corner” or “curved vertex” between the side leg portions 98 ofthe body 95 and does not include a transverse linear component. Incontrast, the nose portion 599 of the body portion 595 of the shapingmember 590 includes a transverse linear component which extends in adirection perpendicular to the upstream-downstream direction.

[0117] As was indicated above, the shaping member 590 may be used withthe separator device 574 and the constant entry device 580. However, theshaping member 590 may be advantageously incorporated into a cushioningconversion machine without these devices, or with any other cushioningconversion machine or method which falls within the scope of the claims.Also, certain portions of the shaping member 590 may be advantageouswhen it is desired to change certain features of a cushioning product.For example, if it were desired to increase the loft of a cushioningproduct, the wing portions 610 could be added to a shaping member.Additionally or alternatively, if it were desired to decrease the amountof stock material which is inwardly turned to form the central portionof the cushioning product, the rib 620 could be added to a shapingmember. A further addition or alternative is to modify the downstreamend of a shaping member to include a transverse linear component.

[0118] Although the invention has been shown and described with respectto certain preferred embodiments, equivalent alterations andmodifications will occur to others skilled in the art upon reading andunderstanding this specification and the annexed drawings. In particularregard to the various functions performed by the above describedintegers (components, assemblies, devices, compositions, etc.), theterms (including a reference to a “means”) used to describe suchintegers are intended to correspond, unless otherwise indicated, to anyinteger which performs the specified function of the described integer(i.e., that is functionally equivalent), even though not structurallyequivalent to the disclosed structure which performs the function in theherein illustrated exemplary embodiment or embodiments of the invention.In addition, while a particular feature of the invention may have beendescribed above with respect to only one of several illustratedembodiments, such feature may be combined with one or more otherfeatures of the other embodiments, as may be desired and advantageousfor any given or particular application.

What is claimed:
 1. A cushioning conversion machine comprising a conversion assembly which converts a sheet stock material into a three dimensional cushioning product and a stock supply assembly which supplies the stock material to the conversion assembly; the conversion assembly including a forming assembly which inwardly turns lateral portions of the stock material as the stock material travels therethrough in a downstream direction; the stock supply assembly including at least one transversely extending member upstream of the forming assembly that is positioned to engage the stock material before the stock material enters the forming assembly; the at least one transversely extending member having end portions that taper inwardly relative to the central portions of the member and outwardly toward the adjacent ends of the member to allow inward urging of the lateral portions of the stock material in a same direction as the inward turning of the stock material in the forming assembly.
 2. A cushioning conversion machine as set forth in claim 1, wherein the at least one transversely extending member includes at least one roller.
 3. A cushioning conversion machine as set forth in claim 1, wherein the at least one transversely extending member is a constant-entry roller that provides a substantially constant entry position for the stock material supplied to the conversion assembly as the stock material is supplied from the stock supply assembly.
 4. A cushioning conversion machine as set forth in claim 1, wherein the stock material has a plurality of plies, and the at least one transversely extending member includes a plurality of separating members which are positioned upstream of the forming assembly to engage respective plies of the stock material; the plurality of transversely extending separating members forming a separating device which separates the plies of the stock material upstream of the forming assembly.
 5. A cushioning conversion machine as set forth in claim 1, wherein the inwardly tapered end portions occupy between 2% and 6% of the combined axial length of the end portions and the central portion.
 8. A cushioning conversion machine as set forth in claim 1, wherein the at least one transversely extending member includes a rod which is non-rotatably supported and a sleeve that rotates relative to the rod.
 9. A cushioning conversion machine as set forth in claim 1, wherein the inwardly tapered outer end portions of the at least one transversely extending member have a curved profile.
 10. A cushioning conversion method comprising the steps of supplying a sheet stock material and converting the stock material into a three dimensional cushioning product; said converting step including the step of inwardly turning lateral portions of the stock material as the stock material travels in a downstream direction; said supplying step including dispensing the stock material from a continuous sheet of stock material and engaging the at least one ply of stock material with a transversely extending member that allows the inward urging of the lateral end portions of the stock material in the same direction as the inwardly turning step of the converting step.
 11. A cushioning conversion method as set forth in claim 10, wherein the supplying step includes the step of separating the plies of a multi-ply stock material and wherein said engaging step is performed at the same time as said separating step.
 12. A cushioning conversion method as set forth in claim 10, wherein said engaging step is accomplished by engaging the at least one ply of stock material with a transversely extending member having end portions that taper inwardly relative to the central portions of the member and outwardly toward the respective ends of the member and that are positioned to engage the ends of the lateral portions of the stock material whereby these ends may be inwardly urged.
 13. A cushioning conversion method as set forth in claim 10, including the step of passing the stock material by a transversely extending constant-entry roller to supply the stock material to a conversion assembly from a substantially constant entry position as the stock material is supplied.
 14. A cushioning conversion machine comprising a conversion assembly which converts a sheet stock material into a three-dimensional cushioning product as it travels therethrough in a downstream direction, and a stock supply assembly upstream of the conversion assembly that supplies the stock material to the conversion assembly; a transversely extending member positioned to engage the stock material, the transversely extending member having lateral end portions and a central portion therebetween extending along an axis, the lateral end portions having a radial cross-sectional shape that decreases in size along an axial dimension in directions away from the central portion.
 15. A cushioning conversion machine as set forth in claim 14, wherein the lateral end portions have a curved profile.
 16. A cushioning conversion machine as set forth in claim 15, wherein the lateral end portions have a circular cross-sectional shape.
 17. A cushioning conversion machine as set forth in claim 15, wherein the lateral end portions have a truncated parabolic shape.
 18. A cushioning conversion machine as set forth in claim 14, wherein the at least one transversely extending member includes a non-rotatable rod and a sleeve rotatably mounted around the rod, the sleeve defining at least the central portion of the at least one transversely extending member.
 19. A cushioning conversion machine as set forth in claim 18, wherein the at least one transversely extending member includes a pair of end caps connected to each end of the sleeve that form the inwardly tapered lateral end portions.
 20. A cushioning conversion machine as set forth in claim 14, wherein the sleeve is cylindrical and has a circular radial cross-sectional shape which has substantially the same size along its axial dimension.
 21. A cushioning conversion machine as set forth in claim 14, wherein the sleeve has a circular radial cross-sectional shape which changes size along its axial dimension.
 22. A cushioning conversion machine as set forth in claim 14, wherein the sleeve also forms the inwardly tapered lateral end portions of the at least one transversely extending member. 